Ribbon filament and assembly for use in extrusion-based digital manufacturing systems

ABSTRACT

A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This is a divisional application of U.S. patent application Ser. No.12/612,333, filed on Nov. 4, 2009, and entitled “Non-CylindricalFilament For Use In Extrusion-Based Digital Manufacturing Systems”;which claims priority to U.S. Provisional Patent Application No.61/247,067, filed on Sep. 30, 2009, and entitled “Non-CylindricalFilament For Use In Extrusion-Based Digital Manufacturing Systems”.

BACKGROUND

The present disclosure relates to direct digital manufacturing systemsfor building three-dimensional (3D) models. In particular, the presentinvention relates to consumable materials, such as modeling and supportmaterials, for use in extrusion-based digital manufacturing systems.

An extrusion-based digital manufacturing system (e.g., fused depositionmodeling systems developed by Stratasys, Inc., Eden Prairie, Minn.) isused to build a 3D model from a digital representation of the 3D modelin a layer-by-layer manner by extruding a flowable consumable modelingmaterial. The modeling material is extruded through an extrusion tipcarried by an extrusion head, and is deposited as a sequence of roads ona substrate in an x-y plane. The extruded modeling material fuses topreviously deposited modeling material, and solidifies upon a drop intemperature. The position of the extrusion head relative to thesubstrate is then incremented along a z-axis (perpendicular to the x-yplane), and the process is then repeated to form a 3D model resemblingthe digital representation.

Movement of the extrusion head with respect to the substrate isperformed under computer control, in accordance with build data thatrepresents the 3D model. The build data is obtained by initially slicingthe digital representation of the 3D model into multiple horizontallysliced layers. Then, for each sliced layer, the host computer generatesa build path for depositing roads of modeling material to form the 3Dmodel.

In fabricating 3D models by depositing layers of a modeling material,supporting layers or structures are typically built underneathoverhanging portions or in cavities of objects under construction, whichare not supported by the modeling material itself. A support structuremay be built utilizing the same deposition techniques by which themodeling material is deposited. The host computer generates additionalgeometry acting as a support structure for the overhanging or free-spacesegments of the 3D model being formed. Consumable support material isthen deposited from a second nozzle pursuant to the generated geometryduring the build process. The support material adheres to the modelingmaterial during fabrication, and is removable from the completed 3Dmodel when the build process is complete.

SUMMARY

A first aspect of the present disclosure is directed to a ribbonfilament for use in an extrusion-based digital manufacturing system witha ribbon liquefier to build a three-dimensional model in alayer-by-layer manner. The ribbon filament includes a compositioncomprising at least one extrudable material, and a length that iscontinuous for at least a distance such that the ribbon filament isfeedable from a supply source to the ribbon liquefier retained by amoveable head of the extrusion-based digital manufacturing system. Theribbon filament also includes a cross-sectional profile of the lengththat is axially asymmetric and having a width and a thickness, whereinthe width ranges from about 1.0 millimeter to about 10.2 millimeters,where the thickness ranges from about 0.51 millimeters to about 1.0millimeter, and where the cross-sectional profile of the ribbon filamenthas a cross-sectional aspect ratio of the width to the thickness rangingfrom about 2.5:1 to about 20:1. The ribbon filament exhibits aflexibility such that the ribbon filament does not plastically deform orfracture while retained by the supply source or when fed from the supplysource to the ribbon liquefier, and a Young's Modulus value ranging fromabout 1.0 gigapascal to about 5.0 gigapascals.

Another aspect of the present disclosure is directed to an assembly foruse in an extrusion-based digital manufacturing system with a ribbonliquefier to build a three-dimensional model in a layer-by-layer manner.The assembly includes a supply source configured to engage theextrusion-based digital manufacturing system, and a ribbon filamentretained by the supply source. The ribbon filament includes acomposition comprising at least one extrudable material, and a lengththat is continuous for at least a distance such that the ribbon filamentis feedable from the supply source to the ribbon liquefier retained by amoveable head of the extrusion-based digital manufacturing system. Theribbon filament also includes a rectangular cross-sectional profile ofthe length, which is configured to mate with the ribbon liquefier havingan entrance cross-sectional area A_(e) and a hydraulic diameter D_(h)with the ribbon filament, where D_(h)<0.95√{square root over (A_(e))},and where the rectangular cross-sectional profile has a width and athickness with a cross-sectional aspect ratio of the width to thethickness ranging from about 2.5:1 to about 20:1. The ribbon filamentexhibits a flexibility such that the ribbon filament does notplastically deform or fracture while retained by the supply source orwhen fed from the supply source to the ribbon liquefier, and a Young'sModulus value ranging from about 1.0 gigapascal to about 5.0gigapascals.

Another aspect of the present disclosure is directed to an assembly foruse in an extrusion-based digital manufacturing system with a ribbonliquefier to build a three-dimensional model in a layer-by-layer manner.The assembly includes a container configured to engage theextrusion-based digital manufacturing system, a pathway from thecontainer and configured to extend to a ribbon liquefier retainable by amoveable head of the extrusion-based digital manufacturing system, and aribbon filament at least partially retained within the container andfeedable through the pathway from the container to the ribbon liquefier.The ribbon filament includes a composition comprising at least oneextrudable material, a length, and a rectangular cross-sectional profileof the length, which is configured to mate with the ribbon liquefierhaving an entrance cross-sectional area A_(e) and a hydraulic diameterD_(h) with the ribbon filament, where D_(h)<0.95√{square root over(A_(e))}, and where the rectangular cross-sectional profile has a widthand a thickness with a cross-sectional aspect ratio of the width to thethickness ranging from about 2.5:1 to about 20:1. The ribbon filamentexhibits a flexibility such that the ribbon filament does notplastically deform or fracture while retained by the supply source orwhen fed from the supply source to the ribbon liquefier, and a Young'sModulus value ranging from about 1.0 gigapascal to about 5.0gigapascals.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an extrusion-based digital manufacturingsystem for building 3D models and support structures fromnon-cylindrical filaments of modeling and support materials.

FIG. 2 is a perspective view of a ribbon filament, which is anon-cylindrical filament having a rectangular cross-sectional profile.

FIG. 3 is a sectional view of section 3-3 taken in FIG. 2, illustratingthe cross-sectional profile of the ribbon filament.

FIG. 4 is an exploded perspective view of an extrusion head subassemblyof the extrusion-based digital manufacturing system in use with a ribbonfilament, where the extrusion head subassembly includes a rectangularliquefier.

FIG. 5A is a sectional view of section 5A-5A taken in FIG. 4,illustrating the ribbon filament being extruded through the rectangularliquefier.

FIG. 5B is a sectional view of section 5B-5B taken in FIG. 4, furtherillustrating the ribbon filament being extruded through the rectangularliquefier.

FIG. 5C is a sectional view of section 5C-5C taken in FIG. 4,illustrating an inlet cross-sectional profile of the rectangularliquefier.

FIG. 6 is a schematic illustration of a plurality of cylindricalliquefiers superimposed over a rectangular liquefier.

FIG. 7 is a flow diagram of a method of forming ribbon filaments.

FIG. 8 is a perspective view of an extruded sheet used to form ribbonfilaments.

FIG. 9 is a schematic illustration of a sheet extrusion system forforming the extruded sheet.

FIG. 10 is a schematic illustration of a filament-production system forforming ribbon filaments from extruded sheets.

FIG. 11 is an alternative sectional view of section 3-3 taken in FIG. 2,illustrating a first alternative ribbon filament having a singlelaminated surface.

FIG. 12 is an alternative sectional view of section 3-3 taken in FIG. 2,illustrating a second alternative ribbon filament having two laminatedsurfaces.

FIG. 13 is an alternative sectional view of section 3-3 taken in FIG. 2,illustrating a third alternative ribbon filament having two laminatedsurfaces with multiple layers.

DETAILED DESCRIPTION

The present disclosure is directed to non-cylindrical filaments ofmodeling and support materials for use in extrusion-based digitalmanufacturing systems, and methods and systems for manufacturing thenon-cylindrical filaments. As discussed below, the non-cylindricalfilaments are consumable materials capable of being melted and extrudedfrom non-cylindrical liquefiers with reduced response times compared tocylindrical filaments melted and extruded from cylindrical liquefierswith the same volumetric flow rates. This is beneficial for improvingdepositional accuracies and reducing build times, thereby increasingprocess efficiencies for building 3D models and corresponding supportstructures.

As used herein, the term “non-cylindrical filament” refers to a filamentof a modeling or support material having a cross-sectional profile thatis non-circular (e.g., a rectangular cross-sectional profile). This isin comparison to a “cylindrical filament”, which has a cross-sectionalprofile that is circular. Correspondingly, as used herein, the term“non-cylindrical liquefier” refers to a liquefier having a channel witha cross-sectional profile that is non-circular (e.g., a rectangular orarcuate cross-sectional profile) for receiving a non-cylindricalfilament. This is in comparison to a “cylindrical liquefier”, which hasa channel with a cross-sectional profile that is circular for receivinga cylindrical filament.

FIG. 1 is a front view of system 10, which is an extrusion-based digitalmanufacturing system that includes build chamber 12, platen 14, gantry16, extrusion head 18, and supply sources 20 and 22, where extrusionhead 18 is configured to receive and melt successive portions ofnon-cylindrical filaments (not shown in FIG. 1) during a buildoperation. Suitable extrusion-based digital manufacturing systems forsystem 10 include fused deposition modeling systems developed byStratasys, Inc., Eden Prairie, Minn.

Build chamber 12 is an enclosed environment that contains platen 14,gantry 16, and extrusion head 18 for building a 3D model (referred to as3D model 24) and a corresponding support structure (referred to assupport structure 26). Platen 14 is a platform on which 3D model 24 andsupport structure 26 are built, and moves along a vertical z-axis basedon signals provided from a computer-operated controller (referred to ascontroller 28). Gantry 16 is a guide rail system configured to moveextrusion head 18 in a horizontal x-y plane within build chamber 12based on signals provided from controller 28. The horizontal x-y planeis a plane defined by an x-axis and a y-axis (not shown in FIG. 1),where the x-axis, the y-axis, and the z-axis are orthogonal to eachother. In an alternative embodiment, platen 14 may be configured to movein the horizontal x-y plane within build chamber 12, and extrusion head18 may be configured to move along the z-axis. Other similararrangements may also be used such that one or both of platen 14 andextrusion head 18 are moveable relative to each other.

Extrusion head 18 is supported by gantry 16 for building 3D model 24 andsupport structure 26 on platen 14 in a layer-by-layer manner, based onsignals provided from controller 28. Extrusion head 18 includes a pairof non-cylindrical liquefiers (not shown in FIG. 1), where the firstnon-cylindrical liquefier is configured to receive and melt successiveportions of a non-cylindrical, modeling material filament, and thesecond non-cylindrical liquefier is configured to receive and meltsuccessive portions of a non-cylindrical, support material filament.

The non-cylindrical, modeling material filament may be provided toextrusion head 18 from supply source 20 through pathway 30. Similarly,the non-cylindrical, support material filament may be provided toextrusion head 18 from supply source 22 through pathway 32. System 10may also include additional drive mechanisms (not shown) configured toassist in feeding the non-cylindrical filaments from supply sources 20and 22 to extrusion head 18. Supply sources 20 and 22 are sources (e.g.,spooled containers) for the non-cylindrical filaments, and are desirablyretained at a remote location from build chamber 12. Suitable assembliesfor supply sources 20 and 22 include those disclosed in Swanson et al.,U.S. Pat. No. 6,923,634; Comb et al., U.S. Pat. No. 7,122,246; andTaatjes et al, U.S. Patent Application Publication Nos. 2010/0096489 and2010/0096485.

During a build operation, gantry 16 moves extrusion head 18 around inthe horizontal x-y plane within build chamber 12, and thenon-cylindrical filaments are fed to extrusion head 18. Extrusion head18 thermally melts the successive portions of the received modelingmaterial filament, thereby allowing the molten material to be extrudedto build 3D model 24. Similarly, extrusion head 18 thermally melts thesuccessive portions of the support material filament, thereby allowingthe molten material to be extruded to build support structure 26. Theupstream, unmelted portions of the non-cylindrical filaments may eachfunction as a piston with a viscosity-pump action to extrude the moltenmaterial out of the respective liquefiers of extrusion head 18.

The extruded modeling and support materials are deposited onto platen 14to build 3D model 24 and support structure 26 using a layer-basedadditive technique. Support structure 26 is desirably deposited toprovide vertical support along the z-axis for overhanging regions of thelayers of 3D model 24. After the build operation is complete, theresulting 3D model 24/support structure 26 may be removed from buildchamber 12, and support structure 26 may be removed from 3D model 24.

As discussed below, the cross-sectional profiles of the non-cylindricalfilaments and liquefiers allow the non-cylindrical filaments to bemelted and extruded from extrusion head 18 with reduced response timescompared to cylindrical filaments and liquefiers. This increases processefficiencies in system 10 for building 3D model 24 and support structure26. For example, reduced response times may increase the accuracy ofstart and stop locations for deposited roads of modeling and supportmaterials. During a build operation to form a layer of a 3D model (e.g.,3D model 24), an extrusion head (e.g., extrusion head 18) is moved in ahorizontal x-y plane and deposits a molten modeling material. After agiven deposition pattern is completed, the extrusion head stopsdepositing the modeling material. This is accomplished by stopping thefilament from being fed into the liquefier of the extrusion head,thereby halting the viscosity-pump action of the filament.

However, the response time between when the extrusion head stops feedingthe filament to the liquefier and when the modeling material actuallystops extruding from the extrusion head is not instantaneous. Instead,there is a delay that is based on factors such as the thermal propertiesof the liquefier, the composition of the filament, and, as discussedbelow, the cross-sectional profile of the filament and liquefierchannel. Similarly, there is also a response time delay associated withthe transition from a zero-flow state to a steady-state flow. Liquefiersand filaments that require large response times increase these delays,thereby potentially decreasing depositional accuracies. Reducing theresponse times, however, can improve the aesthetic and structuralqualities of the resulting 3D model, particularly when building 3Dmodels containing fine features.

For example, a reduced response time for system 10 can gate theacceleration of gantry 16 at suitable locations near the depositionstart and stop points. This can increase the ability to hide the seamsof each layer, which can increase part quality. Additionally, theresponse time determines how far gantry 16 can deviate from a constanttangential velocity as gantry 16 travels around a corner in the x-yplane. As a result, a reduced response time allows extrusion head 18 toachieve greater cornering accelerations and decelerations. This canreduce the production times required to build 3D models and supportstructures, much in the same manner as the cornering capabilities of arace car are important for reducing an overall race time.

For ease of discussion, the following disclosure is made with referenceto a non-cylindrical filament having a rectangular cross-sectionalprofile (referred to as a ribbon filament), and a non-cylindricalliquefier having a corresponding rectangular channel for receiving theribbon filament. The present disclosure, however, is also applicable tonon-cylindrical filaments having a variety of different cross-sectionalprofiles that reduce response times compared to cylindrical filaments.

FIG. 2 is a perspective view of ribbon filament 34, which is anon-cylindrical filament having a rectangular cross-sectional profileand includes length 36. Length 36 is a continuous length that may varydepending on the amount of ribbon filament 34 remaining in supply source20 or 22 (shown in FIG. 1). Ribbon filament 34 is desirably flexiblealong length 36 to allow ribbon filament 34 to be retained in supplysources 20 and 22 (e.g., wound on spools) and to be fed through system10 (e.g., through pathways 30 and 32) without plastically deforming orfracturing. For example, in one embodiment, ribbon filament 34 isdesirably capable of withstanding elastic strains greater than t/r,where “t” is a cross-sectional thickness of ribbon filament 34 in theplane of curvature (e.g., thickness 42, shown in FIG. 3), and “r” is abend radius (e.g., a bend radius in supply source 20 or 22 and/or a bendradius through pathway 30 or 32).

Ribbon filament 34 may be manufactured from a variety of extrudablemodeling and support materials for respectively building 3D model 24 andsupport structure 26 (shown in FIG. 1). Suitable modeling materials forribbon filament 34 include polymeric and metallic materials. In someembodiments, suitable modeling materials include materials havingamorphous properties, such as thermoplastic materials, amorphousmetallic materials, and combinations thereof. Examples of suitablethermoplastic materials for ribbon filament 34 includeacrylonitrile-butadiene-styrene (ABS) copolymers, polycarbonates,polysulfones, polyethersulfones, polyphenylsulfones, polyetherimides,amorphous polyamides, modified variations thereof (e.g., ABS-M30copolymers), polystyrene, and blends thereof. Examples of suitableamorphous metallic materials include those disclosed in U.S. PatentApplication Publication No. 2009/0263582.

Suitable support materials for ribbon filament 34 include materialshaving amorphous properties (e.g., thermoplastic materials) and that aredesirably removable from the corresponding modeling materials after 3Dmodel 24 and support structure 26 are built. Examples of suitablesupport materials for ribbon filament 34 include water-soluble supportmaterials commercially available under the trade designations“WATERWORKS” and “SOLUBLE SUPPORTS” from Stratasys, Inc., Eden Prairie,Minn.; break-away support materials commercially available under thetrade designation “BASS” from Stratasys, Inc., Eden Prairie, Minn., andthose disclosed in Crump et al., U.S. Pat. No. 5,503,785; Lombardi etal., U.S. Pat. Nos. 6,070,107 and 6,228,923; Priedeman et al., U.S. Pat.No. 6,790,403; and Hopkins et al., U.S. Patent Application PublicationNo. 2010/0096072.

The composition of ribbon filament 34 may also include additionaladditives, such as plasticizers, rheology modifiers, inert fillers,colorants, stabilizers, and combinations thereof. Examples of suitableadditional plasticizers for use in the support material include dialkylphthalates, cycloalkyl phthalates, benzyl and aryl phthalates, alkoxyphthalates, alkyl/aryl phosphates, polyglycol esters, adipate esters,citrate esters, esters of glycerin, and combinations thereof. Examplesof suitable inert fillers include calcium carbonate, magnesiumcarbonate, glass spheres, graphite, carbon black, carbon fiber, glassfiber, talc, wollastonite, mica, alumina, silica, kaolin, siliconcarbide, composite materials (e.g., spherical and filamentary compositematerials), and combinations thereof. In embodiments in which thecomposition includes additional additives, examples of suitable combinedconcentrations of the additional additives in the composition range fromabout 1% by weight to about 10% by weight, with particularly suitableconcentrations ranging from about 1% by weight to about 5% by weight,based on the entire weight of the composition.

Ribbon filament 34 also desirably exhibits physical properties thatallow ribbon filament 34 to be used as a consumable material in system10. In one embodiment, the composition of ribbon filament 34 issubstantially homogenous along its length. Additionally, the compositionof ribbon filament 34 desirably exhibits a glass transition temperaturethat is suitable for use in build chamber 12. Examples of suitable glasstransition temperatures at atmospheric pressure for the composition ofribbon filament 34 include temperatures of about 80° C. or greater. Insome embodiments, suitable glass transition temperatures include about100° C. or greater. In additional embodiments, suitable glass transitiontemperatures include about 120° C. or greater.

Ribbon filament 34 also desirably exhibits low compressibility such thatits axial compression doesn't cause ribbon filament 34 to be seizedwithin a liquefier. Examples of suitable Young's modulus values for thepolymeric compositions of ribbon filament 34 include modulus values ofabout 0.2 gigapascals (GPa) (about 30,000 pounds-per-square inch (psi))or greater, where the Young's modulus values are measured pursuant toASTM D638-08. In some embodiments, suitable Young's modulus range fromabout 1.0 GPa (about 145,000 psi) to about 5.0 GPa (about 725,000 psi).In additional embodiments, suitable Young's modulus values range fromabout 1.5 GPa (about 200,000 psi) to about 3.0 GPa (about 440,000 psi).

In some embodiments, as discussed below, ribbon filament 34 may be amulti-layer filament. For example, ribbon filament 34 may include acentral layer disposed between exterior layers of different materials.This allows ribbon filament 34 to exhibit a variety of physical andaesthetic qualities. In additional embodiments, ribbon filament 34 mayexhibit topographical surface patterns at various locations along length36. For example, ribbon filament 34 may include topographical surfacepatterns as disclosed in Batchelder et al., U.S. Patent ApplicationPublication No. 2011/0076495.

FIG. 3 is a sectional view of section 3-3 taken in FIG. 2, illustratingprofile 38 of ribbon filament 34. Profile 38 is an axially asymmetric,cross-sectional profile of ribbon filament 34 at a location along length36. In the shown embodiment, ribbon filament 34 has substantially thesame profile 38 along length 36, thereby allowing the entire length 36to be used during the build operation. Alternatively, one or moreportions of length 36 (e.g., the trailing end segment) may benon-usable.

In the shown embodiment, ribbon filament 34 has a cross-sectional width40 and a cross-sectional thickness 42. Suitable dimensions for width 40and thickness 42 desirably allow ribbon filament 34 to mate with arectangular liquefier of extrusion head 18, and also desirably provide across-sectional aspect ratio that reduces the response time of theextruded material compared to a cylindrical filament in a cylindricalliquefier with the same volumetric flow rate.

Examples of suitable dimensions for width 40 range from about 1.0millimeter (about 0.04 inches) to about 10.2 millimeters (about 0.40inches), with particularly suitable widths ranging from about 2.5millimeters (about 0.10 inches) to about 7.6 millimeters (about 0.30inches), and with even more particularly suitable widths ranging fromabout 3.0 millimeters (about 0.12 inches) to about 5.1 millimeters(about 0.20 inches).

Thickness 42 is desirably thick enough to provide a suitable structuralintegrity for ribbon filament 34, thereby reducing the risk of fracturesor breaks while ribbon filament 34 is retained in supply source 20 or 22and while being fed through system 10 (e.g., through pathways 30 or 32).Examples of suitable dimensions for thickness 42 range from about 0.08millimeters (about 0.003 inches) to about 1.5 millimeters (about 0.06inches), with particularly suitable thicknesses ranging from about 0.38millimeters (about 0.015 inches) to about 1.3 millimeters (about 0.05inches), and with even more particularly suitable thicknesses rangingfrom about 0.51 millimeters (about 0.02 inches) to about 1.0 millimeters(about 0.04 inches).

As discussed below, the aspect ratio of width 40 to thickness 42, and acorresponding aspect ratio of the rectangular liquefier, may be selectedto effectively remove the core that is associated with a cylindricalfilament having a circular cross-section. This allows ribbon filament 34to be melted and extruded in a rectangular liquefier with a reducedresponse time.

FIG. 4 is an exploded perspective view of subassembly 44, which is asuitable subassembly of extrusion head 18 (shown in FIG. 1) for use withribbon filament 34. Subassembly 44 includes drive mechanism 46,liquefier 48, and thermal block 50. Drive mechanism 46 is a filamentdrive mechanism that feeds successive portions of ribbon filament 34from pathway 30 (shown in FIG. 1) to liquefier 48. Drive mechanism 46 isdesirably in signal communication with controller 28 (shown in FIG. 1),thereby allowing controller 28 to direct the rates at which drivemechanism 46 feeds ribbon filament 34 to liquefier 48. While shown as apair of drive wheels, drive mechanism 46 may include a variety ofdifferent mechanisms for feeding ribbon filament 34 to liquefier 48.Examples of suitable filament drive mechanisms for drive mechanism 46include those disclosed in Batchelder et al., U.S. Patent ApplicationPublication Nos. 2009/0274540 and 2009/0273122.

Liquefier 48 is a non-cylindrical liquefier that includes channel 52extending between top end 54 and bottom end 56. Top end 54 and bottomend 56 are opposing ends of liquefier 48 along longitudinal axis 58.Channel 52 is a rectangular slot in which ribbon filament 34 is receivedand melted. Accordingly, the inlet of channel 52 at top end 54 desirablyhas dimensions that allow ribbon filament 34 to mate with channel 52.This allows ribbon filament 34 to slide into channel 52 without unduefrictional resistance. Channel 52 also desirably exhibits substantiallythe same cross-sectional profile along longitudinal axis 58 between topend 54 and bottom end 56. In alternative embodiments, however, thecross-sectional profile of channel 52 may taper down to a smallercross-sectional area at bottom end 56.

Liquefier 48 also includes extrusion tip 60, which is a small-diametertip that is located at a bottom end 56 and is configured to extrude themolten material of ribbon filament 34 with a desired road width.Examples of suitable inner tip diameters for extrusion tip 60 range fromabout 125 micrometers (about 0.005 inches) to about 510 micrometers(about 0.020 inches).

Thermal block 50 is a heat transfer component that extends around atleast a portion of liquefier 48 and is configured to conduct heat toliquefier 48 and the received ribbon filament 34. Examples of suitableheat transfer components for thermal block 50 include those disclosed inSwanson et al., U.S. Pat. No. 6,004,124; Comb, U.S. Pat. No. 6,547,995;LaBossiere et al., U.S. Publication No. 2007/0228590; and Batchelder etal., U.S. Patent Application Publication No. 2009/0273122. Inalternative embodiments, thermal block 50 may be replaced with a varietyof different heat transfer components that generate and/or transfer heatto liquefier 48, thereby forming a thermal gradient within liquefier 48along longitudinal axis 58.

During a build operation in system 10 (shown in FIG. 1), ribbon filament34 is engaged with drive mechanism 46 and loaded into channel 52 ofliquefier 48. Controller 28 then directs drive mechanism 46 drivesuccessive portions of ribbon filament 34 through liquefier 48. Asribbon filament 34 passes through liquefier 48, the thermal gradientgenerated by thermal block 50 melts the material of ribbon filament 34within liquefier 48. The upstream, unmelted portion of ribbon filament34 being driven by drive mechanism 46 functions as a piston with aviscosity pump acting on the molten material between the unmeltedportion and the walls of liquefier 48, thereby extruding the moltenmaterial out of extrusion tip 60. The extruded material may then bedeposited as roads to form 3D model 24 in a layer-by-layer manner.

As discussed above, ribbon filament 34 is capable of being melted andextruded from liquefier 48 with reduced response times compared tocylindrical filaments melted and extruded from cylindrical liquefierswith the same volumetric flow rates. For cylindrical liquefiers, theresponse is dominated by RC-like lumped parameters. As such, theresponse time for cylindrical liquefiers refers to the 1/e time, whichis the time for the flow rate to change from 0% to within about 63% of anew steady state value. In comparison, for non-cylindrical liquefierssuch as liquefier 48, the response is dominated by transmission-lineparameters. As such, the response time for non-cylindrical liquefierssuch as liquefier 48 refers to the time between about the 10% and aboutthe 90% flow rate changes.

For example, the response time of subassembly 44 is the time requiredfor the flow rate of the molten material at extrusion tip 60 to respondto a change in the drive pressure that drive mechanism 46 applies toribbon filament 34 (due to commands from controller 28). Low responsetimes are helpful for improving the aesthetic and structural qualitiesof the resulting 3D model, particularly when building 3D modelscontaining fine features. In particular, low response times arenecessary for building 3D models at high speeds, since it determines thedegree that a gantry (e.g., gantry 16) can slow down going into a cornerand subsequently speed up as it leaves the corner.

The “volumetric flow rate” refers to the thermally-limited, maximumvolumetric flow rate through a liquefier, which is the maximumvolumetric flow rate of a material that a liquefier can liquefy to anextrudable state and then extrude. For a cylindrical liquefier, thethermally-limited, maximum volumetric flow rate Q_(max,c) may bedetermined pursuant to Equation 1:

Q _(max,c)=2πκL _(p,c)

where κ is the thermal diffusivity of the material of a cylindricalfilament, and L_(p,c) is the length of the cylindrical liquefiercontaining molten material. Thus, based solely on this characteristic,the volumetric flow rate Q_(max,c) can be increased merely by increasingthe length of the cylindrical liquefier containing molten material.

However, in a cylindrical liquefier having a particular diameter,increasing the flow rate Q_(max,c) also increases the flow resistance,which correspondingly increases the response time. The response time maybe represented by a lumped, pressure change time constant τ_(c), whichis the product of the flow resistance and the flow capacitance of thecylindrical liquefier and filament material. The flow resistance FR_(c)for the cylindrical liquefier in pressure per (volume per second) may bedetermined pursuant to Equation 2:

${FR}_{c} = \frac{128\mspace{14mu} \eta \mspace{14mu} L_{p,c}}{\pi \mspace{14mu} d_{c}^{4}}$

where η is the dynamic viscosity of the material of the cylindricalfilament, and d_(c) is the inner diameter of the cylindrical liquefier.The flow capacitance FC_(c) for the cylindrical liquefier may bedetermined pursuant to Equation 3:

${FC}_{c} = \frac{\pi \; d_{c}^{2}L_{p,c}}{4B}$

where B is the bulk modulus of the filament material (i.e., thematerial's resistance to uniform compression).

By combining the flow resistance and the flow capacitance of thecylindrical liquefier, the response time for the cylindrical liquefier,based on a lumped, pressure change time constant τ_(c), may bedetermined pursuant to Equation 4:

$\tau_{c} = \frac{32\; \eta \; L_{p,c}^{2}}{{Bd}_{c}^{2}}$

Combining Equations 1 and 4 illustrates the proportional relationshipbetween the time constant τ_(c) and the volumetric flow rate Q_(max,c)for the cylindrical liquefier, which is shown in Equation 5:

$\tau_{c} = \frac{8\eta \; Q_{\max,c}^{2}}{\pi^{2}\kappa^{2}{Bd}_{c}^{2}}$

As shown in Equation 5, increasing the volumetric flow rate of materialcorrespondingly increases the response time, thereby undesirablyincreasing the time required for the pressure of the molten material atan extrusion tip to respond to a change in drive pressure on thecylindrical filament.

One potential technique for reducing the response time is to increasethe diameters of the cylindrical filament and liquefier. However,cylindrical filaments having diameters greater than about 2.5millimeters (about 0.1 inches) become difficult to handle and manage inan extrusion-based digital manufacturing system. As such, for a givenvolume in a cylindrical liquefier, an increase in the volumetric flowrate of the material undesirably increases the response time, and viceversa. These competing factors effectively limit the achievable responsetimes and volumetric flow rates for cylindrical liquefiers.

FIGS. 5A and 5B are sectional views of sections 5A-5A and 5B-5B taken inFIG. 4, respectively, which illustrate ribbon filament 34 being meltedin liquefier 48. As shown in FIG. 5A, thermal block 50 is configured toextend around and heat a portion of the length of liquefier 48 (referredto as heated length 62). Examples of suitable heated lengths 62 forliquefier 48 range from about 13 millimeters (about 0.5 inch) to about130 millimeters (about 5.0 inches), with particularly suitable lengths88 ranging from about 25 millimeters (about 1.0 inch) to about 51millimeters (about 2.0 inches).

As ribbon filament 34 is driven into channel 52 of liquefier 48,successive portions of ribbon filament 34 are melted to at least anextrudable state to form melt pool 64 of the molten material in channel52. As shown, melt pool 64 extends along axis 58 between bottom end 56and meniscus 66. Accordingly, the length of liquefier 48 containing meltpool 64 along axis 58 (referred to as length 68) extends between bottomend 56 and meniscus 66. The location of meniscus 66 within liquefier 48may vary depending on factors such as the thermal profile alongliquefier 48, the dimensions of liquefier 48, the material of ribbonfilament 34, the drive rate of ribbon filament 34, and the like.However, during steady state extrusion, meniscus 66 may be maintained ata substantially constant level such that length 68 of melt pool 64 istypically less than heated length 62.

As respectively shown in FIGS. 5A and 5B, channel 52 of liquefier 48 hasa cross-sectional width (referred to as width 70) and a cross-sectionalthickness (referred to as thickness 72), where width 70 is greater thanthickness 72. This if further illustrated in FIG. 5C, which shows aninlet cross-sectional profile of channel 52 (referred to as channelprofile 74). Suitable dimensions for width 70 and thickness 72 desirablyallow ribbon filament 34 to mate with channel 52, as discussed above. Asalso discussed above, channel profile 74 also desirably exhibitssubstantially the same dimensions along heated length 62 of liquefier 48(shown in FIGS. 5A and 5B). In alternative embodiments, however, channelprofile 74 may taper down to a smaller cross-sectional area adjacent tobottom end 56 of liquefier 48 (shown in FIGS. 4, 5A, and 5B). Inadditional alternative embodiments, channel profile 74 may taper up to alarger cross-sectional area to provide stability to the meniscusposition.

Suitable dimensions for width 70 and thickness 72 at channel profile 74include widths the allow ribbon filament 34 to mate with channel 52without undue friction. Examples of suitable dimensions for width 70range from about 1.0 millimeter (about 0.04 inches) to about 12.7millimeters (about 0.50 inches), with particularly suitable widthsranging from about 3.0 millimeters (about 0.12 inches) to about 10.1millimeters (about 0.40 inches), and with even more particularlysuitable widths ranging from about 3.8 millimeters (about 0.15 inches)to about 6.4 millimeters (about 0.25 inches).

Examples of suitable dimensions for thickness 72 range from about 0.25millimeters (about 0.01 inches) to about 2.5 millimeters (about 0.10inches), with particularly suitable thicknesses ranging from about 0.51millimeters (about 0.02 inches) to about 2.0 millimeters (about 0.08inches), and with even more particularly suitable thicknesses rangingfrom about 0.76 millimeters (about 0.03 inches) to about 1.8 millimeters(about 0.07 inches).

While not wishing to be bound by theory, it is believed that the aspectratio of channel profile 74 effectively removes the core that isassociated with a cylindrical filament having a circular cross-section.This allows liquefier 48 to achieve reduced response times compared to acylindrical liquefier having the same wetted channel volume (e.g., thevolume of channel 52, which is the area of channel profile 74 takenalong length 68, shown in FIGS. 5A and 5B). Ignoring the heat diffusingfrom the edges of ribbon filament 34, assuming that width 70 is largecompared to thickness 72, the time-dependant temperature profile ofribbon filament 34 may be determined pursuant to Equation 6:

${{Temp}( {x,t} )} = {{Temp}_{a} + {( {{Temp}_{f} - {Temp}_{a}} ){\sum\limits_{n = 0}^{\infty}{( {- 1} )^{n}\{ {{{erfc}( \frac{{( {{2n} + 1} )T_{f}} - {2x}}{4\sqrt{\kappa \; t}} )} + {{erfc}( \frac{{( {{2n} + 1} )T_{f}} + {2x}}{4\sqrt{\kappa \; t}} )}} \}}}}}$

where Temp_(a) is an initial temperature of ribbon filament 34 prior tobeing heated in liquefier 48, Temp_(f) is the temperature of liquefier48, T_(f) is the thickness of ribbon filament 34 (i.e., thickness 42),where −T_(f)<2x<T_(f), and where erfc is the complimentary errorfunction as shown in Equation 7:

${{erfc}(x)} = {\frac{2}{\pi}{\int_{x}^{\infty}{{\exp ( {- t^{2}} )}{t}}}}$

The complimentary error function has an asymptotic expansion as shown inEquation 8:

${{erfc}(x)} = {\frac{^{- x^{2}}}{x\sqrt{\pi}}\lbrack {1 + {\sum\limits_{n = 0}^{\infty}{( {- 1} )^{n}\frac{1,3,5,{\ldots \mspace{14mu} ( {{2n} - 1} )}}{( {2x^{2}} )^{n}}}}} \rbrack}$

From Equation 8, the characteristic lowest-order time constant can beextracted, which may be represented by Equation 9:

$\tau_{f} = \frac{T_{f}^{2}}{16\; \kappa}$

Incorporating the first one-hundred terms of the asymptotic expansion inEquation 8, using a thermal diffusivity κ of 8.13 millimeters/second²(0.320 inches/second²) (a suitable value for ABS materials), a thicknessT_(f) of ribbon filament 34 (i.e., thickness 42) of 0.76 millimeters(0.03 inches), an initial temperature Temp_(a) of 80° C., and a walltemperature Temp_(f) of liquefier 48 of 320° C., a reasonable time forthe average temperature to move half-way to the asymptotic temperature,as represented by the lowest-order time constant τ_(f), is about 0.24seconds. Accordingly, a reasonable estimate for the time required toheat ribbon filament 34 is about four times the lowest-order timeconstant τ_(f) (i.e., 4τ_(f)). Thus, this process produces a volume ofthe molten material in 4τ_(f) seconds as determined pursuant to Equation10:

Q(4τ_(f))=(W _(r))(T _(r))(L _(p,r))

where W_(r) is the width of channel 52 (i.e., width 70), T_(r) is thethickness of channel 52 (i.e., thickness 72), and L_(p,r) is the lengthof channel 52 containing molten material (i.e., length 68).

Accordingly, for a rectangular liquefier (e.g., liquefier 48), thethermally-limited, volumetric flow rate Q_(max,r) may be determinedpursuant to Equation 11:

$Q_{\max,r} = {4\kappa \; L_{p,r}\frac{W_{r}}{T_{r}}}$

As shown in Equation 11, the thermally-limited, maximum volumetric flowrate Q_(max,r) is governed by the length of liquefier 48 containing themolten material (i.e., length 68). Thus, the operative length is theheated length of ribbon filament 34 rather than the heated length of theliquefier (e.g., heated length 62).

As discussed above for the cylindrical liquefier, the response time fora rectangular liquefier (e.g., liquefier 48) is also the product of theflow resistance and the flow capacitance of the rectangular liquefierand ribbon filament material. The flow resistance FR, for therectangular liquefier may be determined pursuant to Equation 12:

${FR}_{r} = \frac{12\; \eta \; L_{p,r}}{W_{r}T_{r}^{3}}$

The flow capacitance FC_(r) for the rectangular liquefier may bedetermined pursuant to Equation 13:

${FC}_{r} = \frac{W_{r}T_{r}L_{p,r}}{B}$

By combining the flow resistance and the flow capacitance of therectangular liquefier, the response time τ_(r) for the rectangularliquefier may be determined pursuant to Equation 14:

$\tau_{r} = \frac{12\; \eta \; L_{p,r}^{2}}{{BT}_{r}^{2}}$

Combining Equations 11 and 14 illustrates the proportional relationshipbetween the response time τ_(r) and the volumetric flow rate Q_(max,r)for the rectangular liquefier, which is shown in Equation 15:

$\tau_{r} = \frac{3\eta \; Q_{\max,r}^{2}}{4\kappa^{2}{BW}_{r}^{2}}$

A comparison of Equations 5 and 15 shows that, for the samethermally-limited, maximum volumetric flow rates (i.e.,Q_(max,c)=Q_(max,r)), when width 40 of ribbon filament 34 is greaterthan thickness 42 of ribbon filament 34, the response time forcontrolling the extrusion of ribbon filament 34 in liquefier 48 is lessthan the response time for a cylindrical filament in a cylindricalliquefier. For the same thermally-limited, maximum volumetric flow rates(i.e., Q_(max,c)=Q_(max,r)), the aspect ratio of profile 38 of ribbonfilament 34 and channel profile 74 of channel 52 desirably provides aresponse time that is at least 1.5 times faster than a response timeachievable with a cylindrical liquefier having a circularcross-sectional profile. More desirably, the response time is at leasttwo times faster, and even more desirably is at least three timesfaster. Accordingly, examples of suitable aspect ratios of width 40 tothickness 42 include aspect ratios of about 2:1 or greater, withparticularly suitable aspect ratios ranging from about 2.5:1 to about20:1, with even more particularly suitable aspect ratios ranging fromabout 3:1 to about 10:1, and with even more particularly suitable aspectratios ranging from about 3:1 to about 8:1.

The comparison of Equations 5 and 15 may be visualized by superimposingmultiple cylindrical liquefiers in an array to form a slot comparable tochannel profile 74 of channel 52, as shown in FIG. 6. This results inthe same cross-sectional areas for the cylindrical liquefiers (referredto as cylindrical liquefiers 76) and channel profile 74, ignoring theinterstitial spaces between cylindrical liquefiers 76. Accordingly, inthis example, the diameter of each cylindrical liquefier 76 is the sameas thickness 72. It is also assumed that the lengths of each cylindricalliquefier 76 containing molten material is the same as length 68 of meltpool 64. As such the combined wetted volumes of cylindrical liquefiers76 is the same as the wetted volume of liquefier 48.

The ratio of the response time of the cylindrical liquefier to theresponse time of liquefier 48 τ_(c)/τ_(r) is shown in Equation 16:

$\frac{\tau_{r}}{\tau_{c}} = {\frac{3\pi^{2}d_{c}^{2}}{32\; W_{r}^{2}} = {0.93\; \frac{d_{c}^{2}}{W_{r}^{2}}}}$

Thus, as shown in Equation 16, for the same thermally-limited, maximumvolumetric flow rates (i.e., Q_(max,c)=Q_(max,r)), the ratio of theresponse time of the cylindrical liquefier to the response time ofliquefier 48 is proportional to the diameter of the cylindricalliquefier squared over thickness 72 of channel 52 squared. For example,a cylindrical liquefier having a diameter of 1.78 millimeters (0.070inches) and liquefier 48 having width 70 of 3.05 millimeters (0.120inches) and thickness 72 of 0.813 millimeters (0.032 inches) (i.e., anaspect ratio of about 4:1) have substantially the same cross-sectionalareas. Thus, for these cross-sectional areas, and the same melt poollengths (e.g., length 68), and Q_(max,c)=Q_(max,r), pursuant to Equation16, the response time ratio τ_(r)/τ_(c)=0.32. In other words, theresponse time for liquefier 48 with ribbon filament 34 is about threetimes faster than the response time achievable with the cylindricalliquefier and the cylindrical filament.

In another example, a cylindrical liquefier having a diameter of 1.78millimeters (0.070 inches) and liquefier 48 having width 70 of 4.19millimeters (0.165 inches) and thickness 72 of 0.584 millimeters (0.023inches) (i.e., an aspect ratio of about 7:1) also have substantially thesame cross-sectional areas. Thus, for these cross-sectional areas, andthe same molten lengths, and Q_(max,c)=Q_(max,r), pursuant to Equation16, the response time ratio τ_(r)/τ_(c)=0.167. In other words, in thisexample, the response time for liquefier 48 and ribbon filament 34 isabout six times faster than the response time achievable with thecylindrical liquefier and the cylindrical filament. This illustratesthat as the aspect ratios of ribbon filament 34 and channel 52 increase,the response times also increase.

While again not wishing to be bound by theory, it is believed that thisreduction in response time is due to the fact that the array ofcylindrical liquefiers contain additional wall sections that effectivelyform webs in the cross-sectional area of rectangular liquefier 48,thereby increasing frictional resistance. This increased frictionalresistance is not found in channel profile 74. As such, for a giventhermally-limited, maximum volumetric flow rate, liquefier 48 is capableof receiving, melting, and extruding ribbon filament 34 with a reducedresponse time compared to a cylindrical liquefier and a cylindricalfilament.

The above-discussed embodiments were directed to a non-cylindricalfilament having a rectangular cross-sectional profile (i.e., ribbonfilament 34), and a non-cylindrical liquefier having a correspondingrectangular channel (i.e., liquefier 48). The cross-sectional profilesof these embodiments may be properly characterized by cross-sectionalaspect ratios of width to thickness (e.g., width 40 to thickness 42 ofribbon filament 34, and width 70 to thickness 72 of channel 52).However, many non-cylindrical filaments and liquefiers may havecross-sectional profiles that cannot be properly characterized bycross-sectional aspect ratios of width to thickness. As such, analternative manner for properly characterizing the cross-sectionalprofiles of non-cylindrical filaments and liquefiers may be made with ahydraulic diameter D_(h), as represented by Equation 17:

$D_{h} = \frac{4A_{e}}{U}$

where A_(e) is the area of the cross-sectional profile at the entranceof the liquefier channel, and U is the wetted perimeter of the liquefierchannel.

For a cylindrical liquefier, Equation 17 reduces to D_(h)=D_(c). For arectangular liquefier such as liquefier 48, where channel 52 issubstantially filled with the molten material, A_(e)=W_(r)T_(r), andU=2(W_(r)+T_(r)), and the hydraulic diameter D_(h) may be represented byEquation 18:

$D_{h} = \frac{2W_{r}T_{r}}{W_{r} + T_{r}}$

Accordingly, suitable cross-sectional profiles for non-cylindricalfilaments and liquefiers of the present disclosure desirably havehydraulic diameters D_(h) that are represented by Equation 19:

D _(h) <P ₁√{square root over (A_(e))}

where P₁ is a percentage value such that D_(h) is less than percentageP₁ of √{square root over (A_(e))}. Examples of suitable values forpercentage P₁ include about 0.95 (i.e., D_(h)<0.95√{square root over(A_(e))}), with particularly suitable values percentage P₁ includingabout 0.90 (i.e., D_(h)<0.90√{square root over (A_(e))}), and with evenmore particularly suitable values percentage P₁ including about 0.87(i.e., D_(h)<0.87√{square root over (A_(e))}).

Equation 19 illustrates suitable upper limits for the hydraulicdiameters D_(h) of the non-cylindrical filaments and liquefiers of thepresent disclosure. Accordingly, the suitable cross-sectional profilesfor non-cylindrical filaments and liquefiers of the present disclosurealso desirably have hydraulic diameters D_(h) that are represented byEquation 20:

D _(h) >P ₂√{square root over (A_(e))}

where P₂ is a percentage value such that D_(h) is greater thanpercentage P₂ of √{square root over (A_(e))}. Examples of suitablevalues for percentage P₂ include about 0.40 (i.e., D_(h)>0.40√{squareroot over (A_(e))}), with particularly suitable values percentage P₂including about 0.55 (i.e., D_(h)>0.55√{square root over (A_(e))}), andwith even more particularly suitable values percentage P₂ includingabout 0.70 (i.e., D_(h)>0.70√{square root over (A_(e))}). Thus, thehydraulic diameters D_(h) of the non-cylindrical filaments andliquefiers of the present disclosure desirably meet the criteria ofEquation 19, desirably meet the criteria of Equation 20, and even moredesirably meet the criteria of Equation 19 and of Equation 20. Thesevalues correspond to the above-discussed suitable cross-sectional aspectratios for a rectangular liquefier such as liquefier 48. In comparison,cylindrical filaments and liquefiers require P₁ and P₂ to each be about2.25.

FIGS. 7-11 illustrate suitable embodiments for manufacturingnon-cylindrical filaments, such as ribbon filament 34 (shown in FIGS.2-4), prior to use in extrusion-based digital manufacturing systems(e.g., system 10, shown in FIG. 1). FIG. 7 is a flow diagram of method78, which is an example of a suitable method for manufacturingnon-cylindrical filaments, such as ribbon filament 34. As shown, method78 includes steps 80-88, and initially involves supplying a feedmaterial to a sheet extrusion system (step 80). The feed material may besupplied to the production system in a variety of different media, suchas pellets, rods, powders, particulates, blocks, ingots, and the like.Suitable compositions for the feed materials include those discussedabove for the modeling and support materials of ribbon filament 34.

Upon being supplied to the sheet extrusion system, the feed material maybe melted and extruded to produce an extruded sheet of the feed material(step 82). As discussed below, the extruded sheet may subsequently beused and separated into a plurality of individual ribbon filaments,where the thickness of the extruded sheet in a solid state desirablymatches the thickness of each of the ribbon filaments. After beingextruded, the extruded sheet is desirably cooled to at least partiallysolidify the extruded sheet (step 84). In some embodiments, as discussedbelow, the sheet may also be laminated with additional sheets ofdifferent materials to form a multi-layer sheet.

At this point in the process, the sheet may be stored (e.g., wound up ona take-up spool) for subsequent separation or directly fed to a sheetcutter, such as in a continuous process. At the sheet cutter, the sheetmay be cut longitudinally into the plurality of ribbon filaments, wherethe cross-sectional profile of at least one of the ribbon filaments isdesirably configured to mate with a non-cylindrical liquefier (e.g.,liquefier 48), as discussed above (step 86). More desirably, each of theribbon filaments cut from the extruded sheet are configured to mate witha non-cylindrical liquefier (e.g., liquefier 48).

After being cut, the ribbon filaments may then be loaded onto supplyassemblies (step 88). In one embodiment, the loading process for theplurality of ribbon filaments may be performed in a substantiallyparallel manner, where after being cut from the extruded sheet, theribbon filaments are fed onto multiple take-up spools in a substantiallycontinuous manner. The supply assemblies may then be used in one or moreextrusion-based digital manufacturing systems (e.g., system 10) forbuilding 3D models and support structures.

FIG. 8 is a perspective view of sheet 90, which is an example of anextruded sheet that may be produced pursuant to steps 80, 82, and 84 ofmethod 78 (shown in FIG. 7). As shown in FIG. 8, sheet 90 may be cutinto a plurality of ribbon filaments 92, where each ribbon filament 92desirably corresponds to ribbon filament 34 (shown in FIGS. 2-4). Thenumber of ribbon filaments 92 that may be produced from a single sheet90 may vary depending on the width of sheet 90 (referred to as sheetwidth 94). Examples of suitable numbers of ribbon filaments 92 that maybe extruded from a single sheet 90 range from about five to about onehundred, with particularly suitable numbers ranging from about ten toabout fifty.

Sheet width 94 of sheet 90 desirably minimizes the amount of wastedmaterial. As such, cut ribbon filaments 92 desirably extend across theentire sheet width 94. In alternative embodiments, however, one or moreportions along the sheet width 94 of sheet 90 may be discarded orrecycled. For example, the lateral edge portions of the width of sheet90 may be discarded or recycled, as desired. Examples of suitabledimensions for sheet width 94 range from about 0.3 meters (about 1.0foot) to about 1.2 meters (about 4.0 feet) with particularly suitablewidths ranging from about 0.46 meters (about 1.5 feet) to about 0.91meters (about 3.0 feet).

Additionally, sheet 90, in a solidified state, desirably has a sheetthickness (referred to as sheet thickness 96) that is substantially thesame as the desired thicknesses of ribbon filaments 92 (e.g., thickness42 of ribbon filament 34). Examples of suitable dimensions for sheetthickness 96 range from about 0.08 millimeters (about 0.003 inches) toabout 1.5 millimeters (about 0.06 inches), with particularly suitablethicknesses ranging from about 0.38 millimeters (about 0.015 inches) toabout 1.3 millimeters (about 0.05 inches), and with even moreparticularly suitable thicknesses ranging from about 0.51 millimeters(about 0.02 inches) to about 1.0 millimeters (about 0.04 inches).

After being extruded and at least partially solidified, sheet 90 maythen be cut into ribbon filaments 92, pursuant to step 86 of method 78.This is illustrated in FIG. 8 with a cut line 98 located between eachribbon filament 92. After being cut from extrusion sheet 90, each ribbonfilament 92 may then be loaded onto a supply assembly (e.g., a spool),pursuant to step 88 of method 78. This process allows multiple ribbonfilaments 92 to be fabricated from a single extruded sheet 90 withoutrequiring additional resizing steps to attain the desired thicknessesfor ribbon filaments 92. This correspondingly allows high productionrates to be achieved.

FIG. 9 is a schematic illustration of sheet extrusion system 100, whichis an example of a suitable system for producing extruded sheets (e.g.,sheet 90, shown in FIG. 8) pursuant to method 78 (shown in FIG. 7). Asshown, system 100 includes extrusion assembly 102, cooling drums 104 and106, pulleys 108 and 110, and take-up spool 112. Extrusion assembly 102is configured to receive and extrude a feed material of the desiredmodeling and/or support material (shown as media 114), to produce sheet90. Extrusion assembly 102 includes hopper 116, thermal sleeve 118,drive screw 120 and extrusion outlet 122. While show in a verticalorientation, extrusion assembly 102 (and system 100) may alternativelybe positioned in different orientations (e.g., a horizontalorientation). During operation, drive screw 120 feeds successiveportions of media 114 from hopper 116 to an extrusion shaft defined bythermal sleeve 118 (referred to as extrusion shaft 124). Thermal sleeve118 transfers thermal energy to media 114 as media 114 is fed intoextrusion shaft 122, thereby melting and extruding media 114 out ofextrusion outlet 122 to produce sheet 90.

Sheet 90 may then engage cooling drums 104 and 106 to define thethickness of sheet 90 (i.e., sheet thickness 96). Cooling drums 104 and106 are cylindrical drums that are desirably maintained at reducedtemperatures to cool sheet 90 as sheet 90 engages with cooling drums 104and 106 at nip 126. The reduced temperatures for cooling drums 104 and106 may vary depending on factors such as the line speed of sheet 90,the composition and dimensions of sheet 90, and the like. Examples ofsuitable temperatures for cooling drums 104 and 106 range from about 40°C. to about 60° C. This allows sheet 90 to at least partially solidifyto a solid state while maintaining sheet thickness 96 after passingthrough nip 126.

Accordingly, cooling drum 104 is desirably offset from cooling drum 106at nip 126 at a distance that sets sheet thickness 96 for sheet 90. As aresult, the thicknesses of successive portions of sheet 90 may match thedesired thickness of each ribbon filament 92 that will be cut from sheet90. This allows each ribbon filament 92 to subsequently mate with acorresponding non-cylindrical liquefier (e.g., liquefier 48) to attainreduced response times, as discussed above. In one embodiment, system100 may also include a sensor assembly (not shown) configured to detectand measure the sheet thickness of sheet 90 in real time, and to adjustone or more processing parameters to achieve the desired sheet thickness(e.g., adjusting line speeds, nip dimensions, and the like).

In one embodiment, topographical surface patterns may be formed in sheet90 to provide ribbon filaments 92 having topographical surface patternsas disclosed in Batchelder et al., U.S. Patent Application PublicationNo. 2011/0076495. In this embodiment, one or both of cooling drums 104and 106 may include a textured outer surface configured to form thetopographical surface patterns in sheet 90 when sheet 90. This isbeneficial for forming the topographical surface patterns prior to sheet90 fully solidifying. Alternatively, the patterns in sheet 90 may beformed with the use of additional rollers having textured surfaces,where the additional rollers may be located upstream or downstream fromcooling drums 104 and 106.

In an additional embodiment, system 100 may include one or more coatingunits (not shown) to apply a coating on one or both major surfaces ofsheet 90. For example, system 100 may include a corona discharge unit(not shown) configured to deposit thin coatings of a material on eitheror both major surfaces of sheet 90. This allows a variety of coatingmaterials to be deposited on sheet 90, such as low-surface energymaterials. Low-surface energy materials may be beneficial for reducingfrictional resistance as ribbon filaments 92 are driven into rectangularliquefiers (e.g., liquefier 48) of extrusion-based digital manufacturingsystems (e.g., system 10).

Sheet 90 may then wind around pulleys 108 and 110, and be wound up ontake-up spool 112, where one or more of cooling drums 104 and 106,pulleys 108 and 110, and take-up spool 112 may be motor drive to apply asuitable line speed for forming sheet 90. Examples of suitable linespeeds for forming sheet 90 range from about 1 meter/minute to about 20meters/minute, with particularly suitable line speeds ranging from about5 meters/minute to about 15 meters/minute. In alternative embodiments,additional numbers of pulleys may be used to direct sheet 90 to take-upspool 112. After a suitable length of sheet 90 is wound up on take-upspool 112, sheet 90 may be separated and take-up spool 112 may be storedor set up for subsequent processing to cut sheet 90 into separate ribbonfilaments 92, as discussed below. In an alternative embodiment, sheet 90may be fed directly to a cutting unit to cut sheet 90 into separateribbon filaments 92. In this embodiment, take-up spool 112 may beomitted and sheet 90 may be cut into ribbon filaments 92 in a continuousprocess with the extrusion and forming of successive portions of sheet90.

FIG. 10 is a schematic illustration of filament-production system 128,which is a suitable system for forming ribbon filaments 92 from sheet90. System 128 includes cutting roller 130, backing roller 132, idlerpulleys 134, and take-up spools 136 a-136 d. As shown, sheet 90 may besupplied to the nip intersection of cutting roller 130 and backingroller 132 from a take-up spool (e.g., take-up spool 112) or as a directfeed from system 100 for a continuous process.

Cutting roller 130 is a first roller that includes a cylindrical surfacehaving a plurality of parallel thin blades configured to cut successiveportions of sheet 90 into separate ribbon filaments (referred to asribbon filaments 92 a-92 d). Accordingly, the parallel blades of cuttingroller 130 are desirably separated by gaps that account for the widthsof ribbon filaments 92 (e.g., width 40 of ribbon filament 34, shown inFIG. 3). Cutting roller 130 is also desirably motor driven to pull sheet90 between cutting roller 130 and backing roller 132 during the cuttingoperation. Backing roller 132 is a second roller that is spaced apartfrom cutting roller 130 by a suitable distance to allow sheet 90 to passbetween cutting roller 130 and backing roller 132 and engage with thebladed surface of cutting roller 130.

After being cut from sheet 90, each ribbon filament 92 (e.g., ribbonfilaments 92 a-92 d) is desirably fed to a separate spool of take-upspools 136 a-136 d. Take-up spool 136 a-136 d are examples of suitablesupply assemblies for supply spool 20 and/or supply spool 22 (shown inFIG. 1). Ribbon filaments 92 a-92 d may be directed to the respectivetake-up spools 136 a-136 d with idler pulleys 134. As shown, idlerpulleys 134 are positioned to allow ribbon filaments 92 a-92 d to exitbacking roller 132 at different radial locations. This reduces the riskof ribbon filaments 92 a-92 d from becoming entangled while being loadedto take-up spools 136 a-136 d.

Each of take-up spools 136 a-136 d may also be motor driven torespectively wind up ribbon filaments 92 a-92 d as they are cut fromsheet 90. While system 128 is illustrated with four ribbon filaments 92and four take-up spools 136, cutting roller 130 may cut sheet 90 intoany suitable number of ribbon filaments 92, based on the widths of sheet90 and ribbon filaments 92. The cut ribbon filament 92 may then beloaded onto individual take-up spools 136 in a substantially parallelmanner.

While system 128 is shown with a single cutting roller 130/backingroller 132 pair, in alternative embodiments, system 128 may includemultiple pairs of cutting rollers/backing rollers. For example, system128 may include an initial pair of cutting roller 130 and backing roller132, which may cut sheet 90 into multiple segments, where each segmenthas a width that includes multiple ribbon filaments 92. Each cut segmentmay then pass through an additional pair of cutting roller 130 andbacking roller 132, which may cut the given segment into the separateribbon filaments 92. The separate ribbon filaments 92 may then be loadedonto separate take-up spools 136, as discussed above. Thus, sheet 90 maybe cut into ribbon filaments 92 during a single cutting step or inmultiple successive cutting steps.

Sheet extrusion system 100 and filament-production system 128 are eachdesirably contained within a housing (not shown) to achieve a dryenvironment. For example, systems 100 and 128 may each include a dry aircirculator and/or desiccant packages to maintain the low moisturecontent. Furthermore, take-up spools 112 and 136 may each also includedesiccant packages to keep the received sheet 90/ribbon filament 92 dryduring storage and subsequent use. Suitable techniques for maintainingdry environments in systems 100 and 128, and in take-up spools 112 and136 include those disclosed in Swanson et al., U.S. Pat. No. 6,923,634;Comb et al., U.S. Pat. No. 7,122,246; and Taatjes et al, U.S. PatentApplication Publication Nos. 2010/0096489 and 2010/0096485.

FIGS. 11-13 are alternative sectional views of section 3-3 taken in FIG.2, which illustrate multi-layer ribbon filaments of the presentdisclosure. As shown in FIG. 11, ribbon filament 200 has across-sectional profile similar to that of ribbon filament 34 (shown inFIG. 2). In this embodiment, however, ribbon filament 200 includes baseportion 202 and layer 204, where base portion 202 includes top surface206 and bottom surface 208, and where layer 202 is formed on top surface206. Suitable dimensions for ribbon filament 200 include those discussedabove for ribbon filament 34. Accordingly, examples of suitable widthsfor ribbon filament 200 (referred to as width 210) include thosediscussed above for width 40 of ribbon filament 34. Examples of suitablecombined thicknesses of base portion 202 and layer 204 (referred to asthickness 212) include those discussed above for thickness 42 of ribbonfilament 34.

Suitable materials for base portion 202 include the modeling and supportmaterials discussed above for ribbon filament 34. Layer 204, however,may include different materials from base portion 202 that may assist inthe build operation in system 10 (shown in FIG. 1). For example, manycompositions for water-soluble support materials are relatively brittle,which can result in filament fracturing while being fed through anextrusion-based digital manufacturing system (e.g., system 10). Toreduce the brittleness, layer 204 may be formed on top surface 206 as athin coating from a non-brittle material that is at least partiallysoluble in water. This allows ribbon filament 200 to be fed throughsystem 10 without fracturing or breaking, thereby increasing reliabilityin system 10. Relative to the bulk material of base portion 202, thethin coating of layer 204 provides a small amount of the non-brittlematerial. As such, even if the non-brittle material has a low solubilityin water, the overall composition of support structure 26 has a watersolubility that is close to that of the bulk material used to form baseportion 202, thereby allowing the material of ribbon filament 200 tostill function as a suitable water-soluble support material.

FIGS. 12 and 13 illustrate ribbon filaments 300 and 400, which arealternatives to ribbon filament 200, and where the reference labels areincreased by “100” and “200” respectively. As shown in FIG. 12, ribbonfilament 300 also includes layer 314 formed on bottom surface 308,thereby locating base portion 302 between layers 304 and 314. As shownin FIG. 12, ribbon filament 400 also includes layer 416 disposed betweentop surface 406 and layer 404, and layer 418 disposed between bottomsurface 408 and layer 414. Accordingly, ribbon filaments of the presentdisclosure may include multiple layers, where each of the layers mayinclude the same or different materials depending on the desired layerproperties and on the processes used to form the given layers.

Ribbon filaments 200, 300, and 400 may each be formed generally in thesame manner as discussed above for ribbon filaments 92, which mayinitially involve extruding a base sheet (e.g., sheet 90) with system100, where the base sheet desirably has the same sheet thickness as thethickness respective base portion (e.g., base portions 202, 302, and402) (shown in FIG. 9). One or more layers may then be formed on thebase sheet surface(s) using a variety of coating techniques. The layerformation process is desirably performed prior to cutting the base sheetinto multiple ribbon filaments (e.g., with system 128).

In one embodiment, each layer may be formed by initially forming anadditional extruded sheet having a sheet thickness corresponding to thethickness of the given layer. The additional extruded sheet(s) may thenbe laminated on the base sheet and hot pressed between rollers to securethe layers to the base portion. In this embodiment, layers 416 and 418of ribbon filament 400 may be used as tie layers to receptively securelayers 404 and 414 to base portion 402. The lamination process may beperformed before the base sheet is wound up on a take-up spool (e.g.,take-up spool 112), or, alternatively, the base sheet may be wound up ona take-up spool and subsequently unwound for the lamination process.

In an alternative embodiment, each layer may be formed by depositing orotherwise applying a coating onto the base sheet surface(s). Forexample, each coating may be deposited with a corona discharge unit, asdiscussed above. Alternatively, each coating may be formed with one ormore conventional coating processes, such as knife coating processes androller coating process.

In an additional alternative embodiment, each layer may be formed byco-extruding sheets of each layer along with the base sheet. Thiseliminates the use of a separate lamination or coating step to form thelayer(s) and allows the dimensions of the multi-layer sheet to bedefined with system 100 (e.g., at nip 126).

After the lamination and/or coating process is completed, themulti-layer sheet may then be cut into separate ribbon filaments (e.g.,ribbon filaments 200, 300, and 400) with system 128. The resultingthicknesses of each layer may vary depending on the desiredcharacteristics of the given layer and on the lamination or coatingprocess used. Examples of suitable combined thicknesses for the layersof ribbon filaments 200, 300, and 400 include up to about 50% of thethickness of the ribbon filament (i.e., thickness 212, 312, or 412),with particularly suitable combined thicknesses ranging from about 1% toabout 25% of the thickness of the ribbon filament, and even moreparticularly suitable combined thicknesses ranging from about 5% toabout 25% of the thickness of the ribbon filament.

Ribbon filaments 200, 300, and 400 illustrate suitable examples ofmulti-layer ribbon filaments that may be manufactured with systems 100and 128, and used with system 10 to build 3D models and/or supportstructures with reduced response times. The multi-layer nature of ribbonfilaments 200, 300, and 400 also allow ribbon filaments to be formedfrom extruded sheets (e.g., sheet 90) and attain a variety of differentphysical and aesthetic properties.

In additional embodiments of the present disclosure, the above-discussedcylindrical and non-cylindrical filaments may also be hollow. Since thecross-sectional area of the plastic is reduced by the missing core, thehydraulic diameter of the hollow filament may also be less than thephysical diameter. Accordingly, examples of suitable hydraulic diametersfor the hollow filaments of the present disclosure include thosediscussed above. Furthermore, the liquefier may also include a matingcore to the hollow filament, so that the extrudate is heated from theinside as well as the outside.

One potential additional advantage of a hollow filament is that whenhollow filament is manufactured by rapid extrusion from a compounder, itis desirably rapidly cooled before it is retained on a supply assembly(e.g., spooled). That rapid cooling process may induce diameter changesin an otherwise solid filament that may vary along its length. Incomparison, if a hollow filament is rapidly cooled, the inner surface ofthe hollow filament can vary in diameter, leaving the outer surface moreuniform.

Another potential additional advantage of a hollow filament in the formof a cylindrical shell is compliance with the filament drive mechanism.A solid filament may be close to incompressible, so that a drive rolleror drive teeth may obtain too little or too much traction if thefilament diameter is slightly small or large. A hollow filament,however, provides compliance so that small variations in the filamentdiameter are compensated by variations in the amount of compression ofthe hollow filament.

Yet another potential additional advantage of a hollow filament is thereduced thermal conduction in the inlet of the liquefier. When a solidfilament is stationary, heat may slowly conduct up the center of thefilament to the zone above the heated portion of the liquefier where thewalls are relatively cool. If the filament melts there, it tends tosolidify against the cooler wall, potentially causing a large axialforce to restart filament motion. The rate of heat conduction up ahollow filament, however, will be slower than the rate of conduction upa solid filament due to the lack of a core.

Although the present disclosure has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the disclosure.

1. A ribbon filament for use in an extrusion-based digital manufacturingsystem with a ribbon liquefier to build a three-dimensional model in alayer-by-layer manner, the ribbon filament comprising: a compositioncomprising at least one extrudable material; a length that is continuousfor at least a distance such that the ribbon filament is feedable from asupply source to the ribbon liquefier retained by a moveable head of theextrusion-based digital manufacturing system; and a cross-sectionalprofile of the length that is axially asymmetric and having a width anda thickness, wherein the width ranges from about 1.0 millimeter to about10.2 millimeters, wherein the thickness ranges from about 0.51millimeters to about 1.0 millimeter, and wherein the cross-sectionalprofile of the ribbon filament has a cross-sectional aspect ratio of thewidth to the thickness ranging from about 2.5:1 to about 20:1; whereinthe ribbon filament exhibits a flexibility such that the ribbon filamentdoes not plastically deform or fracture while retained by the supplysource or when fed from the supply source to the ribbon liquefier; andwherein the ribbon filament further exhibits a Young's Modulus valueranging from about 1.0 gigapascal to about 5.0 gigapascals.
 2. Theribbon filament of claim 1, wherein the at least one extrudable materialcomprises a thermoplastic polymeric material.
 3. The ribbon filament ofclaim 1, wherein the cross-sectional profile is configured to mate withthe ribbon liquefier having an entrance cross-sectional area A_(e) and ahydraulic diameter D_(h) with the ribbon filament, whereinD_(h)<0.95√{square root over (A_(e))}.
 4. The ribbon filament of claim3, wherein D_(h)<0.90√{square root over (A_(e))} and D_(h)>0.40√{squareroot over (A_(e))}.
 5. The ribbon filament of claim 1, wherein theribbon filament is configured to mate with the ribbon liquefier in amanner that exhibits a response time for extruding the melted consumablematerial that is at least 50% faster than a response time achievablewith a cylindrical filament in a cylindrical liquefier for a samethermally limited, maximum volumetric flow rate.
 6. The ribbon filamentof claim 1, wherein the ribbon filament further comprises a base portionhaving a first surface and a second surface, and a layer disposed on thefirst surface of the base portion, and wherein the base portion and thefirst surface are derived from different materials.
 7. The ribbonfilament of claim 1, wherein the cross-sectional aspect ratio of thewidth to the thickness ranges from about 3:1 to about 10:1.
 8. Anassembly for use in an extrusion-based digital manufacturing system witha ribbon liquefier to build a three-dimensional model in alayer-by-layer manner, the assembly comprising: a supply sourceconfigured to engage the extrusion-based digital manufacturing system;and a ribbon filament retained by the supply source, the ribbon filamentcomprising: a composition comprising at least one extrudable material; alength that is continuous for at least a distance such that the ribbonfilament is feedable from the supply source to the ribbon liquefierretained by a moveable head of the extrusion-based digital manufacturingsystem; and a rectangular cross-sectional profile of the length, whichis configured to mate with the ribbon liquefier having an entrancecross-sectional area A, and a hydraulic diameter D_(h) with the ribbonfilament, wherein D_(h)<0.95√{square root over (A_(e))}, and wherein therectangular cross-sectional profile has a width and a thickness with across-sectional aspect ratio of the width to the thickness ranging fromabout 2.5:1 to about 20:1; wherein the ribbon filament exhibits aflexibility such that the ribbon filament does not plastically deform orfracture while retained by the supply source; and wherein the ribbonfilament further exhibits a Young's Modulus value ranging from about 1.0gigapascal to about 5.0 gigapascals.
 9. The assembly of claim 8, whereinthe at least one extrudable material comprises a thermoplastic polymericmaterial.
 10. The assembly of claim 8, wherein D_(h)<0.90√{square rootover (A_(e))} and D_(h)>0.40√{square root over (A_(e))}.
 11. Theassembly of claim 8, wherein the supply source comprises a spool onwhich at least a portion of the ribbon filament is wound.
 12. Theassembly of claim 11, wherein the supply source further comprises acontainer, wherein the spool is retained within the container.
 13. Theassembly of claim 8, wherein the width ranges from about 1.0 millimeterto about 10.2 millimeters, wherein the thickness ranges from about 0.51millimeters to about 1.0 millimeter.
 14. An assembly for use in anextrusion-based digital manufacturing system with a ribbon liquefier tobuild a three-dimensional model in a layer-by-layer manner, the assemblycomprising: a container configured to engage the extrusion-based digitalmanufacturing system; a pathway from the container and configured toextend to a ribbon liquefier retainable by a moveable head of theextrusion-based digital manufacturing system; and a ribbon filament atleast partially retained within the container and feedable through thepathway from the container to the ribbon liquefier, the ribbon filamentcomprising: a composition comprising at least one extrudable material; alength; a rectangular cross-sectional profile of the length, which isconfigured to mate with the ribbon liquefier having an entrancecross-sectional area A, and a hydraulic diameter D_(h) with the ribbonfilament, wherein D_(h)<0.95√{square root over (A_(e))} and wherein therectangular cross-sectional profile has a width and a thickness with across-sectional aspect ratio of the width to the thickness ranging fromabout 2.5:1 to about 20:1; wherein the ribbon filament exhibits aflexibility such that the ribbon filament does not plastically deform orfracture while retained by the supply source; and wherein the ribbonfilament further exhibits a Young's Modulus value ranging from about 1.0gigapascal to about 5.0 gigapascals.
 15. The assembly of claim 14,wherein the at least one extrudable material comprises a thermoplasticpolymeric material.
 16. The assembly of claim 14, whereinD_(h)<0.90√{square root over (A_(e))} and D_(h)>0.40√{square root over(A_(e))}.
 17. The assembly of claim 14, and further comprising a spoolretained in the container, wherein at least a portion of the ribbonfilament is wound on the spool.
 18. The assembly of claim 14, andfurther comprising the ribbon liquefier.
 19. The assembly of claim 14,wherein the width ranges from about 1.0 millimeter to about 10.2millimeters, wherein the thickness ranges from about 0.51 millimeters toabout 1.0 millimeter.
 20. The assembly of claim 14, wherein the ribbonfilament further comprises a base portion having a first surface and asecond surface, and a layer disposed on the first surface of the baseportion, and wherein the base portion and the first surface are derivedfrom different materials.